Composite Materials and Applications Thereof

ABSTRACT

Embodiments of the present invention relate to composite materials. In one embodiment, a composite material comprises an inorganic ceramic matrix comprising a first surface and a second surface opposite the first outer surface and generally parallel to the first outer surface. At least one open weave fiber glass fabric is disposed in the inorganic ceramic matrix between the first surface and the second surface. In another embodiment, a composite material comprises a first inorganic ceramic matrix comprising pieces of stone, a second inorganic ceramic matrix attached adjacent to the first inorganic ceramic matrix, and at least one open weave fiber glass fabric disposed in the second inorganic ceramic matrix.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application hereby claims priority under 35 U.S.C. § 119(e)to U.S. Provisional Patent Application Ser. No. 61/175,336 filed May 4,2009, which is incorporated herein by reference, and to U.S. ProvisionalPatent Application Ser. No. 61/179,217 filed May 18, 2009, which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to composite materials and, in particular,to composite materials for potential use in high energy impactapplications such as with ballistics or blast resistance.

BACKGROUND OF THE INVENTION

Materials operable to withstand high energy impacts from various sourcessuch as projectiles and blast compression waves find use in a wide rangeof applications, including civilian and military structuralreinforcement applications. Blast deflection panels, for example, havebeen used to shield buildings and other structures of interest frompotential damage caused by various explosive devices. Moreover, blastresistant construction materials have been incorporated intogovernmental and military buildings as a result of increased efforts tocombat assaults on such structures. The Interagency Security Committee(ISC) of the United States General Services Administration (GSA), forexample, has developed criteria to ensure that security considerations,including blast resistances, play an integral part in the planning,design and construction of federal office buildings and modernizationprojects.

Notwithstanding the importance of such materials in the construction andimprovement of existing structures, there exists a need for a stronger,lighter weight, and more cost effective material. Significantdisadvantages of current blast resistant materials are the associatedhigh structural weights and thicknesses necessary to achieve acceptableblast resistance ratings. For example, conventional materials used forreinforcement include concrete panels that have been moderately toheavily reinforced with structural backup, such as tubes or channels. Asa result of increased weights and thicknesses and the need for heavystructural reinforcements, many blast resistant materials can bedifficult to effectively or efficiently incorporate into new or existingstructures.

SUMMARY

In one aspect, the present invention relates to composite materials. Insome embodiments, the composite materials are blast resistant and/orresistant to ballistics. In some embodiments, a composite material ofthe present invention comprises an inorganic ceramic matrix comprising afirst outer surface and a second outer surface opposite the first outersurface; and at least one open weave fiber glass fabric disposed in theinorganic ceramic matrix between the first outer surface and the secondouter surface. In some embodiments, the composite material furthercomprises a protection layer that is coupled to the second outer layerof the inorganic ceramic matrix. In other embodiments, the compositematerial further comprises a woven fiber glass fabric that is coupled tothe first outer surface of the inorganic ceramic matrix. In yet otherembodiments, the composite material comprises at least three open weavefiber glass fabrics disposed in the matrix between the first outer layerand the second outer layer. In some embodiments, the open weave fiberglass fabrics are spaced evenly throughout the inorganic ceramic matrix.The first and/or second glass fiber fabrics, in some embodiments, areopen weave glass fiber fabrics, such as leno-grid or looper-grid wovenglass fiber fabrics. In some embodiments, the fiber glass fabrics may bepartially coated with a polymer.

In some embodiments, a composite material of the present inventioncomprises a first inorganic ceramic matrix containing pieces of stone,such as granite, and a second inorganic ceramic matrix adjacent to thefirst inorganic ceramic matrix which contains at least one woven or openweave glass fiber fabrics disposed in the second inorganic matrix. Insome embodiments, the composite material further comprises a protectionlayer that is coupled to the second inorganic matrix. In otherembodiments, composite material may comprise a first inorganic ceramicmatrix that may be at least about 0.5 inches thick and the secondinorganic ceramic matrix is at least about 0.5 inches thick. In otherembodiments, the composite material may comprise a first inorganicceramic matrix and a second inorganic ceramic matrix that are each atleast about one inch thick. In still other embodiments the first andsecond inorganic ceramic matrices may be at least about two inchesthick. In yet other embodiments, the first inorganic ceramic matrix maycomprise up to 40% by volume of stone. In alternate embodiments, thefirst ceramic matrix may comprise up to 50% by volume of stone. In someembodiments the first inorganic ceramic matrix may comprise up to about40% by volume of sand. In other embodiments, the first inorganic ceramicmatrix may comprise up to about 50% by volume of sand.

In some embodiments a composite material may be a panel having a lengthand width that are substantially larger than its thickness. In otherembodiments the panel may have a length of at least 7 feet. In otherembodiments, the panel may have a length of at least 13 feet. In stillother embodiments, a panel may comprise four surfaces representing thethickness of the panel with one or more of the surfaces being configuredas a portion of a tapered lap joint to facilitate assembly of multiplepanels. Thus, in some embodiments, the panels may be configured suchthat two or more panels can be coupled using tapered lap-joints. In someembodiments, enough panels can be coupled together via tapered lapjoints to form a wall.

Another aspect of the present invention provides a method of making acomposite material comprising a first inorganic ceramic matrixcomprising a first outer surface and a second outer surface opposite afirst outer surface and generally parallel to the first outer surface;and further comprising at least one open weave fiber glass fabricdisposed in the inorganic ceramic matrix between the first outer surfaceand the second outer surface. In other embodiments, a composite materialmay be formed with a metal frame that surrounds an inorganic ceramicmatrix with a first outer surface and a second outer surface opposite afirst outer surface and generally parallel to the first outer surface;and further comprising at least one open weave fiber glass fabricdisposed in the inorganic ceramic matrix between the first outer surfaceand the second outer surface. In other embodiments, a method is providedfor the formation of a ceramic matrix comprising a first inorganicceramic matrix comprising pieces of stone and sand and a secondinorganic ceramic matrix containing at least one open weave fiber glassfabric dispersed within the second inorganic ceramic matrix wherein thecomposite material is cast within a metal frame that surrounds theinorganic ceramic matrix. In other embodiments the metal frame may be asteel frame. In yet other embodiments, one or more anchors may be usedto further secure the composite material within the frame. In someembodiments, the anchor may comprise a bolt.

In some embodiments, a composite material of the present inventioncomprises a plurality of studs, a deposition layer coupled to theplurality of studs and an inorganic ceramic matrix contacting thedeposition layer and comprising at least one woven glass fiberreinforcement disposed therein. In some embodiments, the at least onewoven glass fiber reinforcement is an open weave glass fiber fabric,such as a leno-grid or looper-grid woven glass fiber fabric.

In some embodiments, an additional layer of spall resistant material maybe attached to a face of the inorganic ceramic matrix. In yet otherembodiments, a spall resistant material may be attached to the inorganicceramic matrix via an epoxy. In still other embodiments, a spallresistant material may be sprayed onto said inorganic ceramic matrix. Inyet other embodiments, a spall resistant material may compriseMil-Tough®.

Composite materials of the present invention can be constructed intopanels or other objects having any desired dimension(s). In someembodiments, the dimensions of the composite materials can be selectedto provide resistance to Department of Defense minimum and GSA mediumand/or high protection level blast loadings per UFC and ISCrequirements. As used herein, “UFC protection level standards” means theU.S. Department of Defense Minimum Antiterrorism Standards forBuildings, Unified Facilities Criteria (UFC) 4-010-01, October 2003,which is hereby incorporated by reference. As used herein, “ISCstandard” means the ISC Security Design Criteria for New Federal OfficeBuildings and Major Modernization Projects, The Interagency SecurityCommittee, U.S. General Services Administration, 2001, which is herebyincorporated by reference. In other embodiments, the dimensions of thecomposite materials can be selected to provide ballistics protection asmeasured by the U.S. Department of Defense Test Method Standard for V₅₀Ballistic Test for Armor, MIL-STD-662F, December 1997 (also referred toherein as “MIL-STD-662F”), which is incorporated herein by reference. Insome embodiments, the composite material may be constructed into panelsdo not require machinery for assembly. In some embodiments, thecomposite material can be constructed into panels that may be carried bytwo people.

In some embodiments, the composite material may be constructed intopanels for use in the construction of new structures. In alternateembodiments, the composite material may be constructed into panels foruse in the construction of portable structures. In other embodiments,the composite material may be constructed into panels that may be usedto retrofit existing structures.

In other embodiments, the composite material may be constructed intopanels with a tapered lap-joint arrangement such that the panels may fittogether into a larger structure. In still other embodiments, thecomposite material may be constructed into panels that are up to eightfeet in length. In some embodiments, the panels may extend up tofourteen feet in length. In some embodiment, the panels may be up to 1.5inches in thickness. In yet other embodiments, the panel may be up to3.5 inches in thickness. In still other embodiments, the panel may be atleast 7 feet in length. In other embodiments, the panel may be at least13 feet in length.

In other embodiments, the composite material may be constructed into ablast protection device having a first wall comprised of an inorganicceramic matrix containing pieces of stone and sand and a second wallcomprised of an inorganic ceramic matrix containing at least one openweave fiber glass fabric dispersed within the inorganic ceramic matrixwherein the first wall and second wall are separated in distance by sixinches. In other embodiments, a blast protection device may furthercomprise a frame within which the first wall and the second wall areretained at a distance from each other of six inches.

In one aspect, the present invention provides methods of makingballistics resistant composite materials. In one embodiment, a method ofmaking a ballistics resistant composite material comprises providing afirst inorganic ceramic matrix containing pieces of stone, such asgranite, dispersed randomly throughout and a second inorganic matrix,which is adhered to the first inorganic ceramic matrix, the secondinorganic ceramic matrix comprising a plurality of woven or open weaveglass fiber fabrics dispersed at even intervals throughout the inorganicmatrix. In some embodiments, the ballistics resistant composite materialmay comprise an inorganic ceramic matrix containing a plurality ofgranite dispersed throughout the inorganic ceramic matrix. In otherembodiments, a spall resistant compound, such as Mil-Tough® may besprayed or adhered to the inorganic ceramic matrix via an epoxy toprevent delamination.

In another aspect, the present invention provides methods of makingblast resistant composite materials. In one embodiment, a method ofmaking a blast resistant composite material comprises providing aninorganic ceramic matrix having a first surface in facing opposition toa second surface and disposing a plurality of woven glass fiberreinforcements in the ceramic matrix. In some embodiments, a first wovenglass fiber fabric is disposed proximate the first surface of theceramic matrix, a second woven glass fiber fabric is disposed proximatethe second surface of the ceramic matrix and at least one additionalwoven glass fiber fabric is disposed between the first and secondfabrics, wherein the at least one additional fabric has a porosity lowerthan the first fabric and/or the second fabric. A plurality ofadditional woven glass fiber fabrics, in some embodiments, can bedisposed between the first and second fabrics. In alternate embodiments,a plurality of woven or open weave glass fiber fabrics are disposed atregular intervals throughout the inorganic ceramic matrix.

In another embodiment, a method of making a blast resistance compositematerial comprises providing a plurality of studs, coupling a depositionlayer to the plurality of studs and depositing an inorganic ceramicmatrix on the deposition layer, the ceramic matrix comprising at leastone woven glass fiber reinforcement disposed therein.

In some embodiments, a method of making a composite material of thepresent invention comprises providing a first inorganic ceramic matrixcontaining pieces of stone, such as granite, dispersed randomlythroughout and a second inorganic ceramic matrix, which is adhered to afirst inorganic ceramic matrix, the second inorganic ceramic matrixcomprising a plurality of woven or open weave glass fiber fabricsdispersed at even intervals throughout the inorganic ceramic matrix. Insome embodiments, the composite material may comprise an inorganicceramic matrix containing a plurality of granite dispersed throughoutthe inorganic ceramic matrix.

In another embodiment, a composite material of the present invention maybe made into a blast or ballistics resistant wall structure. In furtherembodiments, a wall structure according to the present invention maycomprise a first inorganic ceramic matrix containing chunks of granitefixed to a second layer of an inorganic ceramic matrix with a pluralityof woven glass fiber fabric interspersed throughout. In an embodiment,the first and second layers are separated from a third inorganic ceramicmatrix containing a plurality of woven glass fiber fabric that isfixedly attached to a layer to reduce spall by a gap. In someembodiments, the gap is at least six inches.

In various embodiments utilizing an inorganic ceramic matrix, theinorganic ceramic matrix, in some embodiments, can comprise a phosphateceramic matrix.

These and other embodiments of the present invention are described ingreater detail in the detailed description which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A-C illustrates cross-sectional views of composite materialsaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 1 are forillustrative purposes.

FIG. 2A-B illustrates cross-sectional views of composite materialsaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 2 are forillustrative purposes.

FIG. 3 illustrates a cross-sectional view of a blast protection deviceaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 3 are forillustrative purposes.

FIG. 4 illustrates a cross-sectional view of a composite materialaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 4 are forillustrative purposes.

FIG. 5 illustrates a cross-sectional view of a composite materialaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 5 are forillustrative purposes.

FIG. 6 illustrates a cross-sectional view of a composite materialaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 6 are forillustrative purposes.

FIG. 7A-F illustrates cross-sectional views of composite materialsaccording to one embodiment of the present invention. The sizes of thelayers and distances between the layers shown in FIG. 7 are forillustrative purposes.

DETAILED DESCRIPTION

For the purposes of this specification, unless otherwise indicated, allnumbers expressing quantities of ingredients, reaction conditions, andso forth used in the specification are to be understood as beingmodified in all instances by the term “about.” Accordingly, unlessindicated to the contrary, the numerical parameters set forth in thefollowing specification are approximations that can vary depending uponthe desired properties sought to be obtained by the present invention.At the very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter should at least be construed in light of the number ofreported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contains certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Moreover, all ranges disclosed hereinare to be understood to encompass any and all sub ranges subsumedtherein. For example, a stated range of “1 to 10” should be consideredto include any and all sub ranges between (and inclusive of) the minimumvalue of 1 and the maximum value of 10; that is, all sub rangesbeginning with a minimum value of 1 or more, e.g. 1 to 6.1, and endingwith a maximum value of 10 or less, e.g., 5.5 to 10. Additionally, anyreference referred to as being “incorporated herein” is to be understoodas being incorporated in its entirety.

It is further noted that, as used in this specification, the singularforms “a,” “an,” and “the” include plural referents unless expressly andunequivocally limited to one referent.

Various embodiments of the present invention provide composite materialsand methods of making the same. In some embodiments, the compositematerials comprise blast resistant composite materials and methods ofmaking blast resistant composite materials. In some embodiments, blastresistant composite materials of the present invention can be fabricatedinto panels and other objects for the reinforcement of buildings andvarious structures. In some embodiments, composite materials of thepresent invention can provide ballistics protection (e.g., protectionfrom bullets). In alternate embodiments, composite materials of thepresent invention can provide blast resistance protection (e.g.,protection from explosive devices). Composite materials of the presentinvention, in some embodiments, can provide both blast resistance andballistics protection. In additional embodiments, composite materials ofthe present invention may provide resistance to extreme temperatures orfires.

In some embodiments, the composite materials are blast resistant and/orresistant to ballistics. In some embodiments, a composite material ofthe present invention comprises an inorganic ceramic matrix comprising afirst outer surface and a second outer surface opposite the first outersurface; and at least one open weave fiber glass fabric disposed in theinorganic ceramic matrix between the first outer surface and the secondouter surface. In some embodiments, the composite material may furthercomprise a protection layer that is coupled to the second outer layer ofthe inorganic ceramic matrix. In other embodiments, the compositematerial further comprises a woven fiber glass fabric that is coupled tothe first outer surface of the inorganic ceramic matrix. In otherembodiments the composite material further comprises an open weave fiberglass fabric that is disposed at the first outer surface of theinorganic ceramic matrix, a surface fabric. In some embodiments thesurface fabric provides greater resistance to damage from ballistics. Inyet other embodiments, the composite material comprises at least threeopen weave fiber glass fabrics disposed in the matrix between the firstouter layer and the second outer layer. In some embodiments, the openweave fiber glass fabrics are spaced evenly throughout the inorganicceramic matrix. The first and/or second glass fiber fabrics, in someembodiments, are open weave glass fiber fabrics, such as leno-grid orlooper-grid woven glass fiber fabrics. In some embodiments, the fiberglass fabrics may be partially coated with a polymer.

An open weave fiber glass fabric may comprise a fabric that is comprisedof a fiber glass grid of varying weight depending on the desiredapplication. In some embodiments, the fiber glass fabric may becomprised of a fiber glass that is at least about 9 ounces per squareyard in weight. In other embodiments, the fiber glass fabric may becomprised of a fiber glass fabric that is at least about 25 ounces persquare yard in weight. In a preferred embodiment, the fiber glass fabricmay be comprised of a fiber glass that is at least about 14 ounces persquare yard in weight. In yet other embodiments the fiber glass fabricmay be coated with a polymer. The polymer, for example, can assist inholding the fabric together, making the fabric more rigid, and/orfacilitating construction of a composite material of the presentinvention. Such polymers can include thermoplastic or thermosetpolymers. One example of such a polymer is an acrylic polymer.

In some embodiments, the fiber glass fabrics may comprise a void area inthe pattern of the open weave that is large enough such that theinorganic ceramic matrix may contact itself through the void in theweave pattern. In some embodiments, the void opening may be at least0.25 inches. In other embodiments, the void opening may be up to oneinch.

In some embodiments, a composite material may comprise an inorganicceramic matrix comprising a first outer surface and an open weave fiberglass fabric disposed at the first outer surface and a second outersurface opposite the first outer surface with a second open weave glassfiber fabric disposed at the second outer surface with at least one openweave fiber glass fabric disposed between the first outer surface andthe second outer surface within the inorganic ceramic matrix. In otherembodiments the composite material further comprises an open weave fiberglass fabric that is disposed at the first outer surface of theinorganic ceramic matrix, a surface fabric. In some embodiments thesurface fabric provides greater resistance to damage from ballistics. Inother embodiments, the composite material may be at least about 1.5inches in thickness and further comprise at least about four open weavefiber glass fabrics dispersed at equal intervals of about 0.5 inchesthroughout the inorganic ceramic matrix. In yet other embodiments, thecomposite material may be at least about 3.5 inches in thickness andfurther comprise at least about six open weave glass fiber fabricsdisposed within the inorganic ceramic matrix at equal intervals of about0.7 inches.

In other embodiments, a composite material may further comprise aprotection layer that is coupled to the second outer surface of theinorganic ceramic matrix. The protection layer may comprise aspall-resistant material that prevents the deterioration or spalling ofthe inorganic ceramic matrix through exposure to moisture or extremeheat or pressure. Spall occurs when pieces or chunks of concreteseparate and break off from the larger concrete structure. Spalling mayoccur when the concrete is exposed to excessive moisture, temperature orpressure. For example, a fire inside of a concrete structure may causespalling of the concrete due to extreme temperatures. In someembodiments the protection layer is sprayed onto the second outersurface of the inorganic ceramic matrix. In other embodiments theprotection layer is coupled to the second outer surface by an epoxy. Insome embodiments the epoxy may comprise a water cured epoxy. In otherembodiments the protection layer may be Mil-Tough™.

In other embodiments, a composite material comprising an inorganicceramic matrix having a first outer surface and a second outer surfaceopposite a first outer surface and at least one open weave glass fiberfabric disposed between the first outer surface and the second outersurface may also comprise a metal reinforcement. In some embodiments themetal reinforcement may comprise a fine mesh screen. In otherembodiments the metal reinforcement may provide electrical conductivityor magnetic properties to the composite material.

In some embodiments, a composite material of the present inventioncomprises a first inorganic ceramic matrix containing pieces of stone,such as granite, and a second inorganic ceramic matrix adjacent to thefirst inorganic ceramic matrix which contains at least one woven or openweave glass fiber fabrics disposed in the second inorganic matrix. Inother embodiments, the composite material further comprises a protectionlayer that is coupled to the second inorganic matrix. In someembodiments, composite material may comprise a first inorganic ceramicmatrix that contains pieces of stone, such as granite. In someembodiments, the second inorganic matrix may comprise at least one openweave glass fiber fabric and sand. In other embodiments, the sand mayfurther comprise granite sand. In some embodiments, granite sand mayimprove the compressive qualities of the composite material.

In some embodiments, the first inorganic ceramic matrix may comprisepieces of granite in varying sizes. In some embodiments the pieces ofgranite may be at least about 0.75 inches in diameter. In otherembodiments the pieces of granite may be less than 0.75 inches indiameter but more than 0.25 inches in diameter. In other embodiments,the granite provided may be 6M in size and shape. In yet otherembodiments, the first inorganic ceramic matrix may comprise up to 40%by volume of stone. In alternate embodiments, the first ceramic matrixmay comprise up to 50% by volume of stone. In some embodiments thesecond inorganic ceramic matrix may comprise up to about 40% by volumeof sand. In other embodiments, the second inorganic ceramic matrix maycomprise up to about 50% by volume of sand.

In some embodiments, the composite material may be comprised of a firstinorganic ceramic matrix that is at least about one inch thick and asecond inorganic ceramic matrix that is at least about one inch thick.In other embodiments, a second inorganic matrix that is at least aboutone inch thick may contain at least six open weave fiber glass fabricsdispersed evenly throughout. In other embodiments the first inorganicmatrix may further comprises an open weave fiber glass fabric that isdisposed at the first outer surface of the inorganic ceramic matrix, asurface fabric. In some embodiments the surface fabric provides greaterresistance to damage from ballistics. In other embodiments, thecomposite material may comprise a first inorganic ceramic matrix and asecond inorganic ceramic matrix that are each at least about 1.5 inchesthick. In an embodiment in which a second inorganic ceramic matrix is atleast about 1.5 inches thick, the second inorganic ceramic matrix maycomprise at least about nine open weave fiber glass fabrics dispersedevenly throughout. In other embodiments the first inorganic matrix mayfurther comprises an open weave fiber glass fabric that is disposed atthe first outer surface of the inorganic ceramic matrix, a surfacefabric. In some embodiments the surface fabric provides greaterresistance to damage from ballistics. In still other embodiments boththe first and second inorganic ceramic matrices may each be at leastabout two inches thick. In an embodiment in which a second inorganicceramic matrix is at least about two inches thick, the second inorganicceramic matrix may comprise at least about twelve open weave fiber glassfabrics dispersed evenly throughout. In other embodiments the firstinorganic matrix may further comprises an open weave fiber glass fabricthat is disposed at the first outer surface of the inorganic ceramicmatrix, a surface fabric. In some embodiments the surface fabricprovides greater resistance to damage from ballistics.

In some embodiments the total thickness of the composite materialcomprising a first inorganic ceramic matrix comprising pieces of stoneand a second inorganic matrix comprising at least one open weave fiberglass fabric and sand may be 2 inches. In other embodiments, the totalthickness of the composite material with a first inorganic matrix and asecond inorganic matrix may be 3 inches. In yet other embodiments, thetotal thickness may be 4 inches.

In yet other embodiments, a composite material comprising a firstinorganic ceramic matrix containing pieces of stone and a secondinorganic ceramic matrix comprising at least one open weave fiber glassfabric and sand may further comprise a protection layer that is coupledto the second inorganic ceramic matrix The protection layer may comprisea spall-resistant material that prevents the deterioration or spallingof the inorganic ceramic matrix through exposure to moisture or extremeheat or pressure. In some embodiments the protection layer is sprayedonto the second outer surface of the inorganic ceramic matrix. In otherembodiments the protection layer is coupled to the second outer surfaceby an epoxy. In some embodiments the epoxy may comprise a water curedepoxy. In other embodiments the protection layer may be Mil-Tough™.

In other embodiments a composite material may be a panel having a lengthand width that are substantially larger than its thickness. In otherembodiments the panel may have a length of at least 7 feet. In otherembodiments, the panel may have a length of at least 13 feet. In stillother embodiments, a panel may comprise four surfaces representing thethickness of the panel with one or more of the surfaces being configuredas a portion of a tapered lap joint to facilitate assembly of multiplepanels. Thus, in some embodiments, the panels may be configured suchthat two or more panels can be coupled using tapered lap-joints. In someembodiments, enough panels can be coupled together via tapered lapjoints to form a wall.

Another aspect of the present invention provides a method of making acomposite material comprising a first inorganic ceramic matrixcomprising a first outer surface and a second outer surface opposite afirst outer surface and generally parallel to the first outer surface;and further comprising at least one open weave fiber glass fabricdisposed in the inorganic ceramic matrix between the first outer surfaceand the second outer surface. In other embodiments, a composite materialmay be formed with a metal frame that surrounds an inorganic ceramicmatrix with a first outer surface and a second outer surface opposite afirst outer surface and generally parallel to the first outer surface;and further comprising at least one open weave fiber glass fabricdisposed in the inorganic ceramic matrix between the first outer surfaceand the second outer surface. In other embodiments, a method is providedfor the formation of a ceramic matrix comprising a first inorganicceramic matrix comprising pieces of stone and sand and a secondinorganic ceramic matrix containing at least one open weave fiber glassfabric dispersed within the second inorganic ceramic matrix wherein thecomposite material is cast within a metal frame that surrounds theinorganic ceramic matrix. In other embodiments the metal frame may be asteel frame. In yet other embodiments, one or more anchors may be usedto further secure the composite material within the frame. In someembodiments, the anchor may comprise a bolt or another protrusionextending from the interior frame wall. When the inorganic ceramicmatrix is added to the frame, the matrix can surround the anchor andhelp secure the frame to the matrix after it cures.

In another embodiment, a composite material of the present invention maybe made into a blast and/or ballistics resistant wall structure. Infurther embodiments, a wall structure according to the present inventionmay comprise a first inorganic ceramic matrix containing chunks ofgranite fixed to a second layer of an inorganic ceramic matrix with aplurality of woven glass fiber fabric interspersed throughout. In anembodiment, the first and second layers are separated from a thirdinorganic ceramic matrix containing a plurality of woven glass fiberfabric that is fixedly attached to a layer to reduce spall by a gap. Insome embodiments, the gap is at least six inches.

In some embodiments, a composite material of the present inventioncomprises a plurality of studs, a deposition layer coupled to theplurality of studs and an inorganic ceramic matrix contacting thedeposition layer and comprising at least one woven glass fiber fabricdisposed therein. In some embodiments, the at least one woven glassfiber fabric is an open weave glass fiber fabric, such as a leno-grid orlooper-grid woven glass fiber fabric. In some embodiments the wovenglass fiber fabric may have an open weave pattern such that theinorganic ceramic matrix may contact itself through the openings in theweave pattern. In some embodiments, the woven glass fiber fabricdisposed between the first and second woven fabrics may have a tightweave pattern that does not allow the inorganic ceramic matrix tocontact itself through the openings in the weave pattern. The tightweave fabric, in some embodiments, may be needled to enhance binding tothe inorganic ceramic matrix. In some embodiments, a plurality ofadditional woven glass fiber fabrics are disposed between the first andsecond fabrics.

The first and/or second glass fiber fabrics, in some embodiments, can beleno-grid woven glass fiber fabrics. In other embodiments, the firstand/or second glass fiber fabrics can be looper-grid woven glass fiberfabrics.

A number of factors can be considered in selecting fiber glass strandsfor use in making tightly woven or open weave fabrics for use inembodiments of the present invention including, for example, the desiredweight per surface area of the fabric, tensile strength of the fabric,desired weave pattern, desired openness of the fabric, cost, and others.Similarly, one skilled in the art may choose one of many commerciallyavailable sizing compositions for the glass fibers based upon a numberof factors including, for example, performance properties of the sizingcompositions, desired flexibility of the resulting fabric, cost, andother factors. Additionally, in some embodiments, a particular weavepattern may be chosen based upon the desired amount of contact of theinorganic ceramic matrix between the gaps in the weave pattern. In someembodiments, a woven glass fiber fabric that is disposed between a firstand second woven fabric disposed within a composite material comprisingan inorganic ceramic matrix may be needled. In yet other embodiments,there may be a plurality of needled woven glass fiber fabrics disposedbetween the first and second woven fabrics. In some embodiments wherethe glass fiber fabrics disposed between the first and second wovenfabrics are needled, needling can result in some fibers being orientedin a z-direction (e.g., not generally parallel to the fabric surface inthe x-y plane) or perpendicular to the fabric surface. In suchembodiments, the needled fibers can assist in holding the inorganicceramic matrix to the fabric and help resist delamination of the fabricfrom the ceramic matrix. The fabrics can be needled using techniquesknown to those of ordinary skill in the art.

In yet other embodiments, the woven glass fiber fabrics that may bedisposed proximate to the first and second surfaces within a compositematerial comprised of an inorganic ceramic matrix may comprise wovenglass fiber fabrics that have been lightly coated with a polymer. Thepolymer, for example, can assist in holding the fabric together, makingthe fabric more rigid, and/or facilitating construction of a compositematerial of the present invention. Such polymers can includethermoplastic or thermoset polymers. One example of such a polymer is anacrylic polymer.

In some embodiments, the composite material may comprise a plurality ofthinner or thicker woven glass fiber fabrics disposed within theinorganic ceramic matrix. In some embodiments, the composite materialmay comprise fewer, thicker woven glass fiber fabrics disposed withinthe inorganic ceramic matrix. In yet other embodiments, the compositematerial may comprise many, thinner woven glass fiber fabrics disposedthroughout the inorganic ceramic matrix. The number and the thickness ofthe woven or open weave glass fiber fabrics that may be contained withina composite material according to the present invention may be selectedbased upon the desired characteristics of the composite material,including, but not limited to, desired properties of the compositematerial, the desired dimensions of the composite material, productioncosts, and other factors.

In some embodiments, a composite material of the present inventioncomprises an inorganic ceramic matrix having a first surface in facingopposition to a second surface and a plurality of woven glass fiberreinforcements disposed in the matrix between the first surface and thesecond surface. In some embodiments, a composite material comprises afirst woven glass fiber fabric proximate the first surface of theinorganic ceramic matrix and a second woven glass fiber fabric proximatethe second surface of the ceramic matrix and at least one additionalwoven glass fiber fabric disposed between the first and second wovenfabrics wherein the at least one additional fabric has a lower porositythan the first fabric and/or the second fabric.

In some embodiments, the composite material may comprise a firstinorganic ceramic matrix that comprises randomly dispersed pieces ofstone, such as granite, throughout and a second inorganic ceramic matrixcoupled to the first inorganic ceramic matrix, the second inorganicceramic matrix comprising a plurality of woven or open weave glass fiberfabrics dispersed throughout at regular intervals.

In some embodiments the composite material may comprise a firstinorganic ceramic matrix containing randomly dispersed, irregularlyshaped pieces of stone, such as granite, attached to a second inorganicceramic matrix, the second inorganic ceramic matrix comprising aplurality of glass fiber fabrics dispersed at regular intervalsthroughout the second inorganic ceramic matrix. The second inorganicceramic matrix, in some embodiments, comprise a plurality of woven glassfiber fabrics and a single open weave glass fiber fabric dispersedevenly throughout the matrix. In some embodiments the woven glass fiberfabrics may be needled to enhance the binding with the inorganic ceramicmatrix. In some embodiments, the second inorganic ceramic matrix maycomprise a plurality of needled woven glass fiber fabrics dispersed atregular intervals throughout the inorganic ceramic matrix. In yet otherembodiments, the second inorganic ceramic matrix may comprise aplurality of open weave glass fiber fabrics, such as looper-gridfabrics, dispersed at regular intervals throughout the inorganic ceramicmatrix. The second inorganic ceramic matrix may, in certain embodiments,comprise a plurality of open weave glass fiber fabrics dispersed atregular intervals throughout the inorganic ceramic matrix and a singlewoven glass fiber fabric disposed at the edge of the inorganic ceramicmatrix.

In still other embodiments, a composite material of the presentinvention may comprise a thicker or thinner first inorganic ceramicmatrix containing randomly dispersed pieces of stone, such as granite,throughout and a thicker or thinner second inorganic ceramic matrixcoupled to the first inorganic ceramic matrix that contains a pluralityof woven or open weave glass fiber fabrics dispersed throughout atregular intervals. In certain embodiments the first inorganic ceramicmatrix may be one inch in thickness and may be coupled to a secondinorganic ceramic matrix that is also one inch in thickness and maycontain up to six woven or open weave glass fiber fabrics dispersedthroughout at regular intervals. The second inorganic ceramic matrix mayalso be coupled to layer of spall resistant material. In someembodiments, the spall resistant material may be coupled to the secondinorganic matrix via an epoxy. In still other embodiments, the firstinorganic ceramic matrix may be one and one half inches thick and may becoupled to a second inorganic ceramic matrix that is also one and onehalf inches thick and may comprise up to nine woven or open weave glassfiber fabrics dispersed throughout at regular intervals. The secondinorganic matrix may also be coupled to a spall resistant material thatmay be coupled to the second inorganic matrix via an epoxy. In certainembodiments the spall resistant material may comprise Mil-Tough™, apolyurea coating commercially available from PPG Industries, Inc.

In some embodiments where the composite material comprises an inorganicceramic matrix that includes randomly dispersed pieces of stone, thefirst inorganic ceramic matrix can be formed from, for example,Grancrete PCW, which is commercially available from Grancrete, Inc. Inother embodiments, the stone may comprise granite. In yet otherembodiments, the ratio of stone to Grancrete PCW may be 1:1. In someembodiments where the composite material comprises a second inorganicceramic matrix that includes one or more glass fiber fabrics, the secondinorganic ceramic matrix can be formed from, for example, two partsGrancrete PCW, which is commercially available from Grancrete, Inc., andone part sand. In yet other embodiments, the inorganic ceramic matrixmay be formed from one part Grancrete and one part sand and contain aplurality of glass fiber fabrics dispersed throughout.

In some embodiments, at least one surface of the composite material maybe sprayed with a polymer. For example, in some embodiments, the surfaceof the composite material that will face the interior of a structure canbe sprayed with a polymer. The polymer, in some embodiments, can limitspall or help prevent loose chunks of the composite material from flyingoff the composite material when the composite material is impacted(either with a blast or ballistics). In some embodiments, a surface ofthe composite material can be coated with a polyurea. One example of analiphatic polyurea that can be applied to some embodiments of compositematerials is Mil-Tough™, which is commercially available from PPGIndustries, Inc. In yet other embodiments, the aliphatic polyurea may beapplied to a second inorganic matrix via an epoxy. In some embodiments,an epoxy may be moisture cured. In still other embodiments, the epoxymay comprise Mil-Tough™ “Spall Master” polyurea coating.

In an embodiment, a composite material of the present inventioncomprising an inorganic ceramic matrix having a first surface in facingopposition to a second surface and a plurality of woven glass fiberreinforcements disposed in the matrix between the first surface and thesecond surface may comprise a fire-resistant composite material. Forexample, in some embodiments, the fire-resistant composite material mayprovide heat resistance of up to and greater than 2000° F.

In some embodiments, a composite material of the present inventioncomprising an inorganic ceramic matrix having a first surface in facingopposition to a second surface and a plurality of woven glass fiberreinforcements disposed in the matrix between the first surface and thesecond surface may comprise a ballistics resistant composite material.In some embodiments, the ballistics resistant composite material mayprovide protection from the penetration of projectiles fired at thecomposite material. For example, in some embodiments, a compositematerial of the present invention may provide improved ballisticsresistance as compared to an inorganic ceramic matrix, which does notcontain glass fiber fabrics. In some embodiments, the composite materialmay provide 50% greater ballistics resistance compared to an inorganicceramic matrix alone. In other embodiments, a composite material of thepresent invention may provide a total resistance to a ballistic threatas measured by MIL-STD-662F. In yet other embodiments, a compositematerial of the present invention may provide UL Level-8 Multi-Strikeresistance to a ballistic threat.

In alternate embodiments, a composite material of the present inventioncomprising an inorganic ceramic matrix having a first surface in facingopposition to a second surface and a plurality of woven glass fiberreinforcements disposed in the matrix between the first surface and thesecond surface may comprise a blast resistant composite material. Insome embodiments, the blast resistant composite material may provideblast resistance that exceeds the medium-level of protection standard ofthe UFC protection level standards. In some embodiments, the blastresistant composite material may provide blast resistance in excess ofthe intermediate-level of protection standard of the UFC protectionlevel standards. For example, in some embodiments, a composite materialof the present invention may exhibit no delamination or spall when ablast load of GSA medium level is applied. In other embodiments, acomposite material according to the present invention may exhibit onlyminor cracking or delamination at a blast load of intermediate levelaccording the protection level standards. In still other embodiments, acomposite material comprising a one and one half inch first inorganicceramic matrix layer and a one and one half inch second inorganicceramic matrix layer may withstand a blast load of high level accordingto the protection level standards.

FIG. 1 illustrates a cross-sectional view of a ballistics resistantcomposite material according to one embodiment of the present invention.In the embodiment shown in FIG. 1, the composite material comprises afirst inorganic ceramic matrix that includes pieces of stone that is oneinch in thickness with an open weave glass fiber fabric positioned atthe strike face of the first inorganic ceramic matrix and a secondinorganic ceramic matrix comprising six open weave glass fiber fabricsand sand that is one inch in thickness and a protection layer that iscoupled to the second inorganic ceramic matrix. As illustrated in FIG.1, the composite material (100) comprises a first inorganic ceramicmatrix (101) comprising pieces of stone and a second inorganic ceramicmatrix (102) comprising at least one open weave glass fiber fabrics(103) and sand and a protection layer (104).

In some embodiments, the plurality of additional open weave fiber glassfabrics (103) can comprise any woven glass fiber fabric not inconsistentwith the objectives of the present invention. In some embodiments, forexample, each of the plurality of additional open weave fiber glassfabrics comprises an approximately 14 ounce per square yard E-glasslooper-grid fabric. In some embodiments, one or more of the fabrics(103) can coated with a polymer.

Moreover, the first and second woven glass fiber fabrics can compriseany woven glass fiber fabric not inconsistent with the objectives of thepresent invention. In some embodiments, for example, the first and/orsecond woven glass fiber fabrics can comprise an approximately 9 ounceper square yard E-glass leno-grid fabric.

In some embodiments, the first and/or second woven glass fiber fabricscan comprise an approximately 25 ounce per square yard E-glass wovenroving.

In some embodiments, the first and/or second woven glass fiber fabricscan be lightly coated with a polymer. The polymer, for example, canassist in holding the fabrics (103) together, making the fabrics morerigid, and/or facilitating construction of a composite material. Suchpolymers can include thermoplastic or thermoset polymers. One example ofsuch a polymer is an acrylic polymer.

FIGS. 1B-C illustrate cross-sectional views of a ballistics resistantcomposite material according to another embodiment of the presentinvention. As illustrated in each of these figures, a composite materialmay comprise a first inorganic ceramic matrix of varying thickness thatcomprise pieces of stone with an open weave fiber glass fabricpositioned at the strike face of the first inorganic ceramic matrix anda second inorganic ceramic matrix of varying thickness that comprises atleast one open weave fiber glass fabric in sand and a protection layerthat is coupled to the second inorganic ceramic matrix. As illustratedin FIGS. 1B-C, the composite material (105, 106) comprises a firstinorganic ceramic matrix (107, 108) containing randomly dispersed,irregularly sized pieces of stone, such as granite (117), and an openweave glass fiber fabric positioned proximate an upper portion of thecomposite material (113). The use of “upper portion” refers only to theorientation of the composite material in the Figures. A second inorganicceramic matrix (109, 110) contains at least one open weave fiber glassfabric (111, 112) dispersed at intervals throughout the second inorganicceramic matrix (109, 110) which is coupled to a protection layer (114,115). In some embodiments, when such composite materials are installedas part of a structure, the portion with the first inorganic ceramicmatrix can be an exterior surface of the structure, and the portion withthe second inorganic ceramic matrix can be positioned toward theinterior of the structure.

FIGS. 2A-B illustrate a cross sectional view of a blast resistantcomposite material of varying thickness comprising an inorganic ceramicmatrix with at least one open weave fiber glass fabric dispersed withinthe inorganic ceramic matrix. As illustrated in FIG. 2A, the compositematerial (200) comprises an inorganic ceramic matrix (202) with fouropen weave fiber glass fabrics (201) dispersed evenly throughout atregular intervals. As illustrated in FIG. 2B, the composite material(203) comprises an inorganic ceramic matrix (204) with six open weavefiber glass fabrics (205) dispersed evenly throughout at regularintervals.

FIG. 3 illustrates a cross-sectional view of a blast protection deviceaccording to one embodiment of the present invention. As illustrated inFIG. 3, the blast protection device (300) comprises a first inorganicceramic matrix (301) containing chunks of granite fixed to a secondlayer of an inorganic ceramic matrix (302) with a plurality of openweave fiber glass fabrics (303) interspersed throughout. In anembodiment, the first and second layers are separated from a thirdinorganic ceramic matrix (305) containing a plurality of woven glassfiber fabric (306) that is fixedly attached to a layer to reduce spall(307) by a gap (304). In some embodiments, the gap is at least sixinches. In some embodiments, when such composite materials are installedas part of a structure, the portion with the first inorganic ceramicmatrix can be an exterior surface of the structure, and the portion withthe second inorganic ceramic matrix can be positioned toward theinterior air gap and the portion with the third inorganic ceramic matrixfacing the interior air gap and the spall liner positioned toward theinterior of the structure.

FIG. 4 illustrates a cross sectional view of a ballistics resistantcomposite material (400) of the present invention that comprises a firstinorganic ceramic matrix (401) containing randomly dispersed,irregularly sized pieces of stone, such as granite (402), said inorganicceramic matrix being configured to be coupled to another compositematerial using a tapered lap-joint arrangement (403). The firstinorganic ceramic matrix (401) is adjacent to a second inorganic ceramicmatrix (404) that comprises a plurality of open weave glass fiberfabrics (405). The second inorganic ceramic matrix (404) is furthercoupled to a protection layer (406) to protect from delamination uponapplication of a blast or ballistics threat.

FIG. 5 represents a cross sectional view of an embodiment of the presentinvention. In the embodiment shown in FIG. 5, the composite materialcomprises an inorganic ceramic matrix having a first surface in facingopposition to a second surface and a plurality of woven or open weavefiber glass fabrics disposed in the matrix between the first surface andthe second surface. As illustrated in FIG. 5, the composite material(500) comprises a first woven or open weave glass fiber fabric (502)proximate to the first surface (503) of the inorganic ceramic matrix(501). A second woven or open weave glass fiber fabric (504) isproximate to the second surface (505) of the inorganic ceramic matrix(501). A plurality of additional woven or open weave glass fiber fabrics(506) are disposed between the first (502) and second (504) glass fiberfabrics.

FIG. 6 represents another embodiment, a composite material (600) of thepresent invention comprises a plurality of studs (601), a depositionlayer coupled to the plurality of studs (602) and an inorganic ceramicmatrix (603) contacting the deposition layer and comprising at least onewoven glass fiber reinforcement (604) disposed therein. In someembodiments, the at least one woven glass fiber reinforcement is aleno-grid woven glass fiber reinforcement.

In yet other embodiments, the woven glass fiber fabric that may bedisposed within the inorganic ceramic matrix of a composite material maycomprise woven glass fiber fabrics that have been lightly coated with apolymer such as an acrylic polymer.

In alternate embodiments, a woven glass fiber fabric that is disposedwithin the composite material comprising a plurality of studs, adeposition layer coupled to the plurality of studs and an inorganicceramic matrix contacting the deposition may be needled. In yet otherembodiments, there may be a plurality of needled woven glass fiberfabrics disposed within the inorganic ceramic matrix.

In another embodiment, the composite material may comprise a pluralityof thinner or thicker woven glass fiber fabrics disposed within theinorganic ceramic matrix. In some embodiments, the composite materialmay comprise fewer, thicker woven glass fiber fabrics disposed withinthe inorganic ceramic matrix. In yet other embodiments, the compositematerial may comprise many thinner woven glass fiber fabrics disposedthroughout the inorganic ceramic matrix.

In an embodiment, a composite material of the present inventioncomprising a plurality of studs, a deposition layer coupled to theplurality of studs and an inorganic ceramic matrix contacting thedeposition layer and comprising at least one woven glass fiberreinforcement disposed therein may comprise a fire-resistant compositematerial. For example, in some embodiments, the fire-resistant compositematerial may provide heat resistance of up to and greater than 2000° F.

In some embodiments, a composite material of the present inventioncomprising a plurality of studs, a deposition layer coupled to theplurality of studs and an inorganic ceramic matrix contacting thedeposition layer and comprising at least one woven glass fiberreinforcement disposed therein may comprise a ballistics resistantcomposite material. In some embodiments, the ballistics resistantcomposite material may provide protection from the penetration ofprojectiles fired at the composite material. In some embodiments, thecomposite material may provide 50% greater ballistics resistancecompared to an inorganic ceramic matrix alone. In some embodiments, acomposite material of the present invention may provide a totalresistance to a ballistic threat as measured by MIL-STD-662F.

In some embodiments, a composite material of the present inventioncomprising a plurality of studs, a deposition layer coupled to theplurality of studs and an inorganic ceramic matrix contacting thedeposition layer and comprising at least one woven glass fiberreinforcement disposed therein may comprise a blast resistant compositematerial. In some embodiments, the blast resistant composite materialmay provide blast resistance that exceeds the medium-level of protectionstandard of the UFC protection level standards. In some embodiments, theblast resistant composite material may provide blast resistance inexcess of the intermediate-level of protection standard of the UFCprotection level standards. For example, in some embodiments, acomposite material of the present invention may exhibit no delaminationor spall when a blast load of GSA medium level is applied. In otherembodiments, a composite material according to the present invention mayexhibit only minor cracking or delamination at a blast load ofintermediate level according the protection level standards.

Also, in some embodiments, the at least one woven glass fiberreinforcement (604) can comprise any woven glass fiber reinforcement notinconsistent with the objectives of the present invention. In someembodiments, for example, the at least one woven glass fiberreinforcement (604) comprises 9 ounces per square yard E-glass leno-gridfabric.

In some embodiments, the at least one woven glass fiber reinforcement(604) comprises an approximately 14 ounces per square yard E-glasslooper-grid fabric.

In some embodiments, the at least one woven glass fiber reinforcement(604) can be lightly coated with a polymer. The polymer, for example,can assist in holding the fabric (604) together, making the fabric (604)more rigid, and/or facilitating construction of a composite material.Such polymers can include thermoplastic or thermoset polymers. Oneexample of such a polymer is an acrylic polymer.

FIGS. 7A-F illustrate cross sectional views of ballistics resistantcomposite materials according to embodiments of the present invention.As is illustrated in each of the figures, a composite material maycomprise a plurality of either woven or open weave fiber glass fabrics,or combinations of both. As illustrated in FIGS. 7A-F, the compositematerial (700, 701, 702, 703, 704, 705) comprises a first inorganicceramic matrix (712, 713, 714, 715, 716, 717) containing randomlydispersed, irregularly sized pieces of stone, such as granite (718, 719,720, 721, 722, 723), proximate an upper portion of the compositematerial. The use of “upper portion” refers only to the orientation ofthe composite material in the Figures. A second inorganic ceramic matrix(724, 725, 726, 727, 728, 729) contains a plurality of woven or openweave glass fiber fabrics (706, 707, 708, 709, 710, 711) dispersed atregular intervals throughout the second inorganic ceramic matrix. Insome embodiments, when such composite materials are installed as part ofa structure, the portion with the first inorganic ceramic matrix can bean exterior surface of the structure, and the portion with the secondinorganic ceramic matrix can be positioned towards the interior of thestructure.

As described herein, composite materials of the present invention cancomprise various fiber glass fabrics including, for example, open weavefiber glass fabrics or more tightly woven fiber glass fabrics. Examplesof open weave fiber glass fabrics can include, for example, leno-grid orlooper-grid woven glass fiber fabrics. Such fabrics are commerciallyavailable from Textum Weaving, Inc. of Belmont, N.C. In selectingfabrics for use in composite materials of the present invention,relevant factors to be considered include the desired flexural strengthof the fabric, the desired weight per surface area of the fabric, thedesired modulus of the fabric, the desired void size (e.g., size of theholes in the grid) of the fabric, and other factors. In someembodiments, for example, the desired void size (e.g., the length of oneside of a void space in the grid) can generally be ⅛ of an inch orgreater. In some embodiments, the desired void size can be 3/16 of aninch or greater. In some embodiments, the desired void size may be ¼ ofan inch or greater. In some embodiments, the desired void size can be upto about an inch. Due to manufacturing variations, the void sizes in aparticular open weave fabric may vary. An open weave fabric may have anominal or desired void size, but the actual voids may fall within arange. For example, and without limitation, the majority of voids in afabric having a nominal void size of ⅜ of an inch may be between ⅛ of aninch and ¼ of an inch in some embodiments.

As noted elsewhere herein, in some embodiments, such open weave fabricscan be lightly coated with a polymer (e.g., polyacrylic) to provide morerigidity to the fabric. One example of an acrylic polymer that can beused in some embodiments is FULATEX PD-0431 commercially available fromH.B. Fuller Company.

Additional information about the open weave fabrics are providedthroughout this application. The weight of the fabric can be selectedbased on a number of factors including, for example, the type of grid(leno vs. looper), the desired strength of the fabric, whether thefabric will be coated with a polymer, and other. In some embodiments,the open weave glass fiber fabric may weigh about 8 oz/yd² or more. Insome embodiments, the open weave glass fiber fabric may weigh about 14oz/yd² or more. In some embodiments, the open weave glass fiber fabricmay be an about 9 oz/yd² leno-grid fabric. In other embodiments, theopen weave glass fiber fabric may be an about 14 oz/yd² looper-gridfabric. In some embodiments, the looper-grid fabric can be constructedusing HYBON® 2026 direct draw roving commercially available from PPGIndustries, Inc.

Composite materials of the present invention can also comprise moretightly woven fiber glass fabrics. Such fabrics, for example, can beconstructed by weaving fiber glass strands in a plain weave usingconventional weaving techniques. The properties of the fiber glassstrands can be selected based on a number of factors including, forexample, the desired flexural strength of the fabric, the desiredmodulus of the fabric, the desired weight of the fabric, cost, and otherfactors. Prior to weaving, such fiber glass strands can be coated withmost commercially available sizing compositions. As one example, suchfabrics can be constructed using HYBON® 2006 direct draw roving (250yield) commercially available from PPG Industries, Inc. In someembodiments, such fabrics may be constructed using HYBON® 2022 directdraw roving commercially available from PPG Industries, Inc. In someembodiments, the tightly woven fiber glass fabric may have a weight ofabout 15 oz/yd² or more. In some embodiments, the tightly woven fiberglass fabric may have a weight of about 18 oz/yd² or more. In someembodiments, the tightly woven fiber glass fabric may have a weight ofup to about 40 oz/yd². In some embodiments, the tightly woven fiberglass fabric may have a weight of approximately 25 oz/yd². In someembodiments, the tightly woven fiber glass fabric may have a weightbetween about 18 oz/yd² and about 25 oz/yd². A suitable weight range oftightly woven fiber glass fabrics for use in embodiments of the presentinvention may be between about 18 oz/yd² and about 36 oz/yd². Additionalinformation about such fabrics are provided throughout this application.

In another aspect, the present invention provides methods of makingblast resistant and/or ballistics resistant composite materials. In oneembodiment, a method of making a blast resistant and/or ballisticsresistant composite material comprises providing an inorganic ceramicmatrix having a first surface in facing opposition to a second surfaceand disposing a plurality of woven glass fiber reinforcements in theceramic matrix. In some embodiments, a first woven glass fiber fabric isdisposed proximate the first surface of the inorganic ceramic matrix, asecond woven glass fiber fabric is disposed proximate the second surfaceof the ceramic matrix and at least one additional woven glass fiberfabric is disposed between the first and second fabrics, wherein the atleast one additional fabric has a porosity lower than the first fabricand/or the second fabric. A plurality of additional woven glass fiberfabrics, in some embodiments, are disposed between the first and secondfabrics.

In alternate embodiments, a method of making a composite materialcomprising a woven glass fiber fabric that is disposed between first andsecond woven fabrics disposed within a an inorganic ceramic matrix maycomprise needling the woven glass fiber fabric. In yet otherembodiments, the method may comprise needling a plurality of woven glassfiber fabrics disposed between the first and second woven fabrics.

In yet other embodiments, a method of making a composite materialcomprising a woven glass fiber fabric that is disposed between first andsecond woven glass fiber fabrics disposed within an inorganic ceramicmatrix may comprise lightly coating the first and woven glass fiberfabrics with a polymer. The polymer, for example, can assist in holdingthe fabric together, making the fabric more rigid, and/or facilitatingconstruction of a composite material of the present invention. Suchpolymers can include thermoplastic or thermoset polymers. One example ofsuch a polymer is an acrylic polymer.

In some embodiments, a method of making the composite material maycomprise providing a plurality of thinner or thicker woven glass fiberfabrics disposed within the inorganic ceramic matrix. In someembodiments, the method may comprise including with the compositematerial fewer, thicker woven glass fiber fabrics. In yet otherembodiments, the method may comprise providing many thinner woven glassfiber fabrics disposed throughout the inorganic ceramic matrix.

In other embodiments, a method of making a composite material maycomprise providing a first inorganic ceramic matrix containing randomlydispersed, irregularly sized pieces of stone, the first inorganicceramic matrix can be formed from, for example, Grancrete PCW, which iscommercially available from Grancrete, Inc. In some embodiments wherethe composite material comprises a second inorganic ceramic matrix thatincludes one or more glass fiber fabrics, the second inorganic ceramicmatrix can be formed from, for example, two parts Grancrete PCW, whichis commercially available from Grancrete, Inc., and one part sand.

In some embodiments, a method of making a composite material maycomprise spraying at least one surface of the composite material maywith a polymer. For example, in some embodiments, the surface of thecomposite material that will face the interior of a structure may besprayed with a polymer. The polymer, in some embodiments, can limitspall or help prevent loose chunks of the composite material from flyingoff the composite material when the composite material is impacted(either with a blast or ballistics). In other embodiments, the polymermay be applied in a layer to the surface of the composite material withan epoxy. In some embodiments, the epoxy may be moisture cured. In someembodiments, the coating may comprise a polyurea. One example of analiphatic polyurea that can be applied to some embodiments of compositematerials is Mil-Tough™, which is commercially available from PPGIndustries, Inc.

In some embodiments, a method of making a composite material of thepresent invention comprising an inorganic ceramic matrix having a firstsurface in facing opposition to a second surface and a plurality ofwoven glass fiber reinforcements disposed in the matrix between thefirst surface and the second surface may comprise providing afire-resistant composite material. For example, the method may comprise,in some embodiments, a fire-resistant composite material that providesheat resistance of up to and greater than 2000° F.

In some embodiments, a method of making a composite material of thepresent invention comprising an inorganic ceramic matrix having a firstsurface in facing opposition to a second surface and a plurality ofwoven glass fiber reinforcements disposed in the matrix between thefirst surface and the second surface may comprise providing a ballisticsresistant composite material. In some embodiments, the method maycomprise a ballistics resistant composite material that protects fromthe penetration of projectiles fired at the composite material. In someembodiments, the composite material may provide 50% greater ballisticsresistance compared to an inorganic ceramic matrix alone. In otherembodiments, a composite material of the present invention may provide atotal resistance to a ballistic threat as measured by MIL-STD-662F.

In some embodiments, a method of making a composite material of thepresent invention comprising an inorganic ceramic matrix having a firstsurface in facing opposition to a second surface and a plurality ofwoven glass fiber reinforcements disposed in the matrix between thefirst surface and the second surface may comprise providing a blastresistant composite material. In some embodiments, the method maycomprise providing a blast resistant composite material with blastresistance that exceeds the medium-level of protection standard of theUFC protection level standards. In alternate embodiments, the method maycomprise a blast resistant composite material that provides blastresistance in excess of the intermediate-level of protection standard ofthe UFC protection level standards. For example, in some embodiments, acomposite material of the present invention may exhibit no delaminationor spall when a blast load of GSA medium level is applied. In otherembodiments, a composite material according to the present invention mayexhibit only minor cracking or delamination at a blast load ofintermediate level according the protection level standards.

In some embodiments, a method of making a blast resistant compositematerial comprises providing a plurality of studs, coupling a depositionlayer to the plurality of studs and depositing an inorganic ceramicmatrix on the deposition layer, the ceramic matrix comprising at leastone woven glass fiber reinforcement disposed therein.

In some embodiments, a method of making a woven glass fiber fabric thatis disposed within the composite material comprising a plurality ofstuds, a deposition layer coupled to the plurality of studs and aninorganic ceramic matrix contacting the deposition may comprise needlingthe woven glass fiber fabric. In yet other embodiments, a plurality ofwoven glass fiber fabrics may be disposed within the inorganic ceramicmatrix.

In yet other embodiments, a method of making a woven glass fiber fabricthat may be disposed within the inorganic ceramic matrix of a compositematerial may comprise lightly spraying woven glass fiber fabrics with anacrylic polymer.

In some embodiments, a method of making a composite material maycomprise including a plurality of thinner or thicker woven glass fiberfabrics disposed within the inorganic ceramic matrix. In someembodiments, method of making a composite material may compriseincluding fewer, thicker woven glass fiber fabrics disposed within theinorganic ceramic matrix. In yet other embodiments, the method of makinga composite material may comprise including many, thinner woven glassfiber fabrics disposed throughout the inorganic ceramic matrix.

In some embodiments, a method of making a composite material of thepresent invention comprising a plurality of studs, a deposition layercoupled to the plurality of studs and an inorganic ceramic matrixcontacting the deposition layer and comprising at least one woven glassfiber reinforcement disposed therein may comprise providing afire-resistant composite material. For example, in some embodiments, themethod may comprise providing a fire-resistant composite material withheat resistance of up to and greater than 2000° F.

In some embodiments, the method of making a composite material of thepresent invention comprising a plurality of studs, a deposition layercoupled to the plurality of studs and an inorganic ceramic matrixcontacting the deposition layer and comprising at least one woven glassfiber reinforcement disposed therein may comprise providing a ballisticsresistant composite material. In some embodiments, the method maycomprise providing a ballistics resistant composite material thatprotects from the penetration of projectiles fired at the compositematerial. In some embodiments, the composite material may provide 50%greater ballistics resistance compared to an inorganic ceramic matrixalone. In other embodiments, a composite material of the presentinvention may provide a total resistance to a ballistic threat asmeasured by MIL-STD-662F.

In some embodiments, a method of making a composite material of thepresent invention comprising a plurality of studs, a deposition layercoupled to the plurality of studs and an inorganic ceramic matrixcontacting the deposition layer and comprising at least one woven glassfiber reinforcement disposed therein may comprise providing a blastresistant composite material. In some embodiments, the method maycomprise providing a blast resistant composite material that exceeds themedium-level of protection standard of the UFC protection levelstandards. In some embodiments, the method may comprise providing ablast resistant composite material that provides blast resistance inexcess of the intermediate-level of protection standard of the UFCprotection level standards. For example, in some embodiments, acomposite material of the present invention may exhibit no delaminationor spall when a blast load of GSA medium level is applied. In otherembodiments, a composite material according to the present invention mayexhibit only minor cracking or delamination at a blast load ofintermediate level according the protection level standards. In yetother embodiments, a composite material according to the presentinvention may withstand a blast load of high level according to theprotection level standards without significant delamination.

Some embodiments of the present invention will now be illustrated in thefollowing specific, non-limiting examples.

Example 1

One example of an embodiment of a composite material according to thepresent invention is as follows. The composite material has a structuresimilar to that shown in FIG. 2. For ease of illustration, the labelsused in FIG. 2 will be used to characterize the components of thecomposite material in this example, but this Example should not beviewed as limiting other embodiments of the present invention that mightalso have a structure similar to that shown in FIG. 2. This embodimentof a composite material 200 is approximately 1.5 inches thick. Thefabrics 201 are lightweight fabrics woven from fiber glass as leno-gridfabrics and weighing approximately nine ounces per square yard. Thefabrics 201 were constructed using two ends of 1200 yield direct drawfiber glass in the warp direction and one end of 550 yield direct drawfiber glass in the fill direction. The composite material 200 comprisesfour total fabrics 201, with one fabric positioned proximate to eachsurface and two fabrics positioned between the two outer fabrics withinthe inorganic ceramic matrix 202. These fabrics 201 were woven in aplain weave using PPG's HYBON® 2006 direct draw roving (250 yield) with5.5 picks per inch in the warp direction and 5.3 picks per inch in theweft direction. The fabrics weigh approximately twenty-five ounces persquare yard. The white areas shown in FIG. 2 represent an inorganicceramic matrix 202 formulated from 2 parts Grancrete PCW (fromGrancrete, Inc.) and 1 part sand. The composite material was formed bydry blending the Grancrete PCW and the sand with a hand held augermixer. The Grancrete/sand mixture was then added to a continuous augermixer with metered water mixed into the dry ingredients. A secondarymixture of further blended inorganic ceramic matrix is then pumped invia a hose into a mold or form. A first layer of leno grid fabric 201was placed into the form and 0.5 inches of the Grancrete/sand mixturewas placed on top of the fabric layer. A second layer of woven rovingwas then place on top of the Grancrete/sand mixture and rolled out. Asecond layer of the Grancrete/sand inorganic ceramic matrix was thenadded and another layer of roving was applied. Finally, a third layer ofinorganic ceramic matrix was applied to the mold/form and a top layer ofleno fabric was added to the top surface.

Example 2

Another example of an embodiment of a composite material according tothe present invention is as follows. The composite material has astructure similar to that shown in FIG. 6. For ease of illustration, thelabels used in FIG. 6 will be used to characterize the components of thecomposite material in this example, but this Example should not beviewed as limiting other embodiments of the present invention that mightalso have a structure similar to that shown in FIG. 6.

The composite material 600 in this Example is a spray-coated compositematerial. The composite material 600 comprises a plurality of metalstuds 601 with screws protruding such that the heads of the screws wouldpenetrate into the other layers. The deposition layer 602 is a polymericfoam, such as Styrofoam and is approximately 0.5 inches thick. Thecomposite material 600 comprises a fabric 604. The fabric 604 is alightweight fabric woven from fiber glass as a leno-grid fabric andweighs approximately nine ounces per square yard. The fabric 604 wasconstructed using two ends of 1200 yield direct draw fiber glass in thewarp direction and one end of 550 yield direct draw fiber glass in thefill direction. The two gray areas shown in FIG. 6 represent aninorganic ceramic matrix 603 formulated from 2 parts Grancrete PCW (fromGrancrete, Inc.) and 1 part sand. The ceramic matrix 603 isapproximately ⅝ of an inch thick with the fabric 604 being positionedapproximately ⅜ of an inch from the outer surface of the compositematerial 200 and approximately ¼ of an inch from the deposition layer602. The composite material of FIG. 6 is a 0.65 inch blast panel thatmay be sprayed onto a stud wall.

As was described in the preceding Example, the Grancrete PCW and sandwere dry blended, mixed with water and then pumped through a hose into aspray dispensing apparatus. The spray device utilizes compressed air todisperse and transfer the inorganic ceramic matrix from the spray deviceto the wall. The first applications of the inorganic ceramic matrix areused to coat the deposition layer (Styrofoam). A layer of leno gridfabric was then affixed to the wet inorganic ceramic matrix using thescrew heads to hang and position the fabric. Three to four more sprayapplications of the inorganic ceramic matrix were then placed over thefabric layer to achieve the final thickness of the wall panel.

Example 3

Some embodiments of the present invention provide improved ballisticthreat protection as measured by MIL-STD-662F. Several samples ofembodiments according to the present invention were tested according tothe standards set forth in MIL-STD-662F and the V₅₀ value as measured inft/sec was measured. The results of this testing are presented in thetable below. The V₅₀ value for some of the samples was unable to becalculated (as designated by N/A) because none of the fired projectilespenetrated the sample.

The panels of Example 3 were constructed by hand mixing the GrancretePCW/sand in a tub with a large drill auger. The construction of thepanels is the same as the construction detailed above in Example 1. The1.5 inch panels each contained four layers of fiber glass fabric andthree layers of inorganic ceramic matrix. The 3.5 inch panels eachcomprised six layers of fiber glass fabric and five layers of inorganicceramic matrix containing two parts Grancrete PCW to one part sand. Inembodiments containing both open weave and woven fabrics, the wovenfabrics were disposed at the middle of the inorganic ceramic matrix andthe open weave fabrics were disposed at the outer edges.

Sample Description Threat Level V₅₀ (ft/s) 1.5″ thick w/regular Hybon.44-Mag., 240-grain SWCGC 1747 Woven Roving (“HWR-25”) and uncoated 9 ozLeno-grid 1.5″ thick w/needled HWR-25 .44-Mag., 240-grain SWCGC 1738 andcoated 14 oz Looper-grid 3.5″ thick w/regular HWR-25 7.62 × 39-mm,123/grain 1965 and uncoated 9 oz Leno-grid MSC 3.5″ thick w/needledHWR-25 7.62 × 39-mm, 123/grain 1992 and coated 14 oz Looper-grid MSC3.5″ thick w/needled HWR-25 .30-06-cal., 180-grain LCSP N/A and coated14 oz Looper-grid 3.5″ thick w/needled HWR-25 7.62 × 51-mm, 150-grainN/A and coated 14 oz Looper-grid M80 copper FMJ 3.5″ thick w/regularHWR-25 .30-06-cal., 165-grain APM2 N/A and uncoated 9 oz Leno-grid

Example 4

Other embodiments of the present invention provide improved ballisticthreat protection as measured by MIL-STD-662F. Several samples ofembodiments according to the present invention were tested according tothe standards set forth in MIL-STD-662F and the V₅₀ value as measured inft/sec was measured. The results of this testing are presented in thetable below.

The panels were constructed as follows. The protection layer comprised aMil-Tough “Spall Master” layer that was 0.1 inch thick and applied as apre-cast film using an epoxy adhesive. In some embodiments, the firstinorganic ceramic matrix layer may comprise granite stone (size #6M,which is about ¾ inch in diameter) blended with Grancrete PCW at a ratioof 1:1 stone to Grancrete. In the high density stone embodiment, thefirst inorganic ceramic matrix comprised stone pieces that were sizedsmaller than the #6M, or approximately 0.5 inches in diameter, and weremixed with Grancrete PCW at a ratio of 2:1 of stone to Grancrete. The5.25 inch panels contained fifteen layers of looper grid fabric, allevenly spaced throughout the second inorganic ceramic matrix. The 3.5inch panels contained seven layers of looper fabric, all evenly spacedthroughout the second inorganic ceramic matrix.

Sample Description Threat Level No. of Strikes V₅₀ (ft/s) 3″ thick w/standard stone construction .30-06 = -cal., 165-grain APM2 9 2525 3″thick w/higher density stone .30-06 = -cal., 165-grain APM2 9 2520construction (smaller size) 5.25″ thick, same construction as blast.30-06 = -cal., 165-grain APM2 9 3662 wall (w/protection layer) 5.25″thick, same construction as blast 50-cal., 695 grain APM2 5 2149 wall(w/protection layer) 5.25″ and 3.5″ thick planks, same as 50-cal., 695grain APM2 2 2861 - Partial blast wall (w/protection layer) 3021 -Partial 5.25″ and 3.5″ thick planks, same as 20-mm, 830 grain FSP 23316 - Partial blast wall (w/protection layer) 3676 - Partial 5.25″thick panel and 3.5″ thick 20-mm, 830 grain FSP 2 4100 - Partial planks,same as blast wall 4380 - Partial (w/protection layer)

Example 5

Some embodiments of the present invention provide improved blast andballistic protection. Several samples of embodiments of the presentinvention were tested under standards for blast and ballisticsprotection. The results of this testing is presented in the table below.The panels were constructed using techniques similar to those describedin Example 1.

NIJ Blast Panel Areal 0108- Stanag Euronorm Protection Type ThicknessDensity 01 UL752 4569 EN 1063 Level Blast & 1.5 inch (with 4 15 LevelsLevels N/A Levels Protection for Ballistic layers of looper lb/ft² I,1-3 B1, B2, wall and roof fabric, one IIA II B3, B4 structure withfabric up to 8-foot positioned at span each outer UFC 4-010-01, surfaceand two GSA low, dispersed medium and evenly high levels throughout) 3.5inch (with 6 35 NIJ Levels Level Level Protection for layers of looperlb/ft² Level 4-5 1 B5, B6 wall and roof fabric, one III structures withfabric up to 14-foot positioned at span each outer UFC 4-010-01, surfaceand 4 GSA other fabrics high-level dispersed evenly throughout)Ballistic 2 inch (panel 25 Levels Levels Level Levels with one inchlb/ft² I, IIA, 1-8 1 B1, B2, thick first II, B3, B4, inorganic III-A,B5, B6 cemmic matrix III comprising granite and a one inch thick secondinorganic matrix comprising 6 looper fiber glass fabrics dispersedthroughout) 3 inch (panel 37 NIJ Level Level Level with 1.5 inch lb/ft²Level 8 2 B6 first inorganic III cemmic matrix comprising granite and a1.5″ thick second inorganic cemmic matrix comprising 9 looper glassfiber fabrics dispersed throughout)

Desirable characteristics, which can be exhibited by embodiments of thepresent invention, can include, but are not limited to, the provision ofcomposite materials having increased resistance to damage resulting fromblasts or ballistics; the provision of composite materials having alighter weight than traditional concrete reinforcements; the provisionof composite materials having increased fire resistance over traditionalbuilding structures; the provision of composite materials having anincreased tensile strength over traditional concrete walls; theprovision of composite materials that are rapidly cured as compared totraditional concrete structures; the provision of the composite materialthat is environmentally superior to concrete; and/or others.

It is to be understood that the present description illustrates aspectsof the invention relevant to a clear understanding of the invention.Certain aspects of the invention that would be apparent to those ofordinary skill in the art and that, therefore, would not facilitate abetter understanding of the invention have not been presented in orderto simplify the present description. Although the present invention hasbeen described in connection with certain embodiments, the presentinvention is not limited to the particular embodiments disclosed, but isintended to cover modifications that are within the spirit and scope ofthe invention.

1-14. (canceled)
 15. A composite material comprising: a first inorganic ceramic matrix comprising pieces of stone; a second inorganic ceramic matrix adjacent to the first inorganic ceramic matrix and different in composition from the first inorganic ceramic matrix; and at least three evenly spaced open weave fiber glass fabrics, having a void opening of at least 0.25 inches, disposed in the second inorganic ceramic matrix; wherein at least one of the first inorganic ceramic matrix and the second inorganic ceramic matrix comprises a phosphate ceramic, and wherein the composite material is at least 1.5 inches thick.
 16. The composite material of claim 15, wherein the stone size is 6M.
 17. The composite material of claim 15, further comprising a protection layer coupled to an outer surface of the second inorganic ceramic matrix.
 18. The composite material of claim 17, wherein the protection layer is a spall-resistant layer.
 19. The composite material of claim 17, wherein the protection layer comprises a polyuria coating.
 20. The composite material of claim 17, wherein the protection layer is coupled to the outer surface with an epoxy.
 21. The composite material of claim 15, wherein the stone is granite.
 22. The composite material of claim 15, wherein the first inorganic ceramic matrix is at least 0.5 inches thick and the second inorganic ceramic matrix is at least 0.5 inches thick.
 23. The composite material of claim 15, wherein the first inorganic ceramic matrix is at least one inch thick and the second inorganic ceramic matrix is at least one inch thick.
 24. The composite material of claim 15, wherein the first inorganic ceramic matrix comprises at about 40 percent stone by volume.
 25. The composite material of claim 15, wherein the first organic ceramic matrix comprises at least 50 percent stone by volume.
 26. The composite material of claim 25, wherein the second organic ceramic matrix comprises at least 40 percent sand by volume.
 27. The composite material of claim 25, wherein the second organic ceramic matrix comprises at least 50 percent sand by volume.
 28. The composite material of claim 15, wherein the second inorganic ceramic matrix comprises sand and a plurality of open weave fiber glass fabrics.
 29. The composite material of claim 15, wherein the composite material is a panel having a length and width that are each substantially larger than its thickness.
 30. The composite material of claim 29, wherein the panel has a length of at least 7 feet.
 31. The composite material of claim 29, wherein the panel has a length of at least 13 feet.
 32. The composite material of claim 15, wherein the at least three open weave fiber glass fabrics comprise a leno-grid fiber glass fabric.
 33. The composite material of claim 15, wherein the at least three open weave fiber glass fabrics weigh less than 25 ounces per square yard.
 34. The composite material of claim 15, wherein the at least three open weave fiber glass fabrics are at least partially coated with a polymer.
 35. The composite material of claim 15, wherein the composite material has a V50 value of at least 1700 ft/s as measured by MIL-STD-662F standard.
 36. A composite material comprising: an inorganic ceramic matrix comprising a first outer surface and a second outer surface opposite the first outer surface and generally parallel to the first outer surface; a plurality of studs; a deposition layer coupled to the plurality of studs; at least one open weave fiber glass fabric disposed in the inorganic ceramic matrix between the first outer surf ace and the second outer surface; wherein the inorganic ceramic matrix comprises a phosphate ceramic and contacts the deposition layer.
 37. The composite material of claim 36, wherein the deposition layer comprises a polymeric foam. 